Insulated glass window spacer and method for making window spacer

Abstract

An integral metal spacer for insulated glass units and method of fabricating the spacer. The spacer defines a substantially closed cross-section contour having a bottom surface, a pair of sidewalls, and a pair of generally abutting inner surfaces. A gap may be defined between the adjacent inner surfaces. The three interior corners are defined by fully mitered sidewalls. A pair of bridges are provided to integrally interconnect the inner surfaces of adjacent spacer segments. The method of fabricating includes taking a roll of flat metal stock and completely punching all corner and other structures therein while the stock is planar; severing the punched stock into individual spacer members; roll-forming the individual members into a finished linear spacer piece; applying desiccant during roll-forming; applying sealant; thereafter folding the elongate member into a square spacer thereby locking the desiccant therein.

It is claimed:  
     
       1. An elongate metallic spacer stock member to be folded into an insulated glass unit spacer comprised of a single continuous metal member; the metal member having a continuous bottom surface along substantially the full length of the metal member, opposed parallel sidewalls extending perpendicularly from the bottom surface and extending along substantially the full length of the metal member, the sidewalls having notches therein that extend the full height of the sidewall from an upper edge thereof downwardly to the bottom surface, the sidewall notches being disposed at, and defining, corner regions of the spacer when the spacer stock is folded, the sidewall notches being further defined in pairs whereby each sidewall defines substantially identical sidewall notches, inner wall members in parallel spaced-apart relationship to the bottom surface and extending substantially along the entire length of the metal member, the inner wall members being continuous along at least the corner regions thereby defining bridge members in the corner regions adjacent the sidewall notches whereby both the bottom surface and the spaced-apart inner wall members define continuous points of interconnection throughout the corner region and positioning a desiccant within the interior of the metallic spacer. 
     
     
       2. The elongate metallic spacer stock member of claim  1  wherein said desiccant is a hot melt desiccant. 
     
     
       3. The elongate metallic spacer stock member of claim  1  including means for locking the desiccant-containing material within the interior of the metallic spacer against any axial movement therein. 
     
     
       4. The elongate metallic spacer stock member of claim  3  in which the corner bridge members deflect inwardly into the interior of the stock member upon the folding of the stock member thereby defining said means for locking the desiccant-containing material within the interior of the metallic spacer against any axial movement therein. 
     
     
       5. The elongate metallic spacer stock member of claim  2  wherein said inner wall members remain spaced apart a sufficient distance to allow insertion of the desiccant therein as the spacer stock member is roll-formed from a flat piece of sheet material. 
     
     
       6. The elongate metallic spacer stock member of claim  5  in which the diameter of the desiccant-containing material is selected whereby the desiccant-containing material is maintained between the inner wall members and the bottom surface as the spacer member is being roll-formed. 
     
     
       7. The elongate metallic spacer stock of claim  5  wherein the amount of desiccant inserted therein is measured by a flow meter. 
     
     
       8. The elongated metallic stock member of claim  7  wherein a nozzle assembly inserts said desiccant inserted therein. 
     
     
       9. An insulated glass unit comprising a folded metallic spacer stock member and glass sheets secured to said spacer, said metallic spacer stock member comprising a continuous bottom surface along substantially the full length of the metal member, opposed parallel sidewalls extending perpendicularly from the bottom surface and extending along substantially the full length of the metal member, the sidewalls having notches therein that extend the full height of the sidewall from an upper edge thereof downwardly to the bottom surface, the sidewall notches being disposed at, and defining, corner regions of the spacer when the spacer stock is folded, the sidewall notches being further defined in pairs whereby each sidewall defines substantially identical sidewall notches, inner wall members in parallel spaced-apart relationship to the bottom surface and extending substantially along the entire length of the metal member, the inner wall members being continuous along at least the corner regions thereby defining bridge members in the corner regions adjacent the sidewall notches whereby both the bottom surface and the spaced-apart inner wall members define continuous points of interconnection throughout the corner region. 
     
     
       10. An insulated glass unit of claim  9  wherein a desiccant is positioned within the interior of the metal spacer.